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Chapter
3
Drilling Hydraulics
From rigging up to laying down the derrick, calculating hydraulics is an
important part of drilling a well economically. Chapter 3 demonstrates
calculations for hydraulic and input horsepower required from the prime mover
for both gravity-feed and supercharged pumps. Equations can be used for
calculating fluid movement through the surface equipment, drillpipe, drill
collars, and bit, as well as back up the annulus to the flowline. These calculations
will help operators determine efficient and economical job procedures.
The tables in Chapter 3 include information about the effects of various job
parameters (the drilling fluids flow rate, weight, and viscosity as well as the
sizes of the pipe, bit nozzle, and cuttings).
October 1996
Drilling Hydraulics
3-1
Problem 1
What is the hydraulic horsepower of a pump delivering 1,260 gal/min at 333
psi? This pump has a suction pressure of 0 psi.
Work Space
Answer ____________
(The solution for Problem 1 is on Page 3-22.)
A comparison of the answers to Example 1 and Problem 1 shows that hydraulic
horsepower output by high pressure and low rate is equal to the hydraulic
horsepower output by low pressure and a high rate. Using high volume instead
of high pressure might seem to be more economical because high pressures are
sometimes difficult to maintain. However, even though the hydraulic horsepower requirements are equal, the high-volume operation may not be as economical because reduced pressure may also decrease penetration rate.
When the mud pump is supercharged (pressurized suction) and is driven by a
separate prime mover, it is necessary to subtract the suction pressure from the
discharge pressure before calculating the hydraulic horsepower. Example 2
demonstrates this calculation. When the same prime mover drives both the
supercharger and the mud pump, the total hydraulic horsepower is calculated as
shown in Example 1.
3-2
October 1996
Problem 2
What is the hydraulic horsepower of a mud pump delivering 210 gal/min at
1,000 psi with a suction pressure of 75 psi?
Work Space
Answer ____________
(The solution for Problem 2 is on Page 3-22.)
October 1996
Drilling Hydraulics
3-3
3-4
October 1996
Problem 3
What input horsepower is necessary for a pump delivering 250 hhp when the
pump efficiency is 80%?
Work Space
Answer ____________
(The solution for Problem 3 is on Page 3-22.)
Problem 4
What input horsepower is required for a mud pump delivering 840 gal/min at
1,100 psi if the pump efficiency is 75% and the suction pressure is 100 psi?
Work Space
Answer ____________
(The solution for Problem 4 is on Page 3-22.)
October 1996
Drilling Hydraulics
3-5
Table 3.2 shows typical pressure losses occurring from the bit to the surface for
the same well conditions described for Table 3.1.
Tables 3.1 and 3.2 show significant pressure losses. Drillpipe is one of the primary sources of pressure losses because of friction. Losses of hydraulic energy
caused by friction can never be recovered, and they must occur so that the
appropriate amount of hydraulic energy can be supplied to the required point in
the system.
This situation is similar to buying a loaf of bread at the store where the total
price includes freight cost. The freight cost cannot be eaten but the loaf of bread
must be at the store; therefore, the freight must be paid. On a drilling rig, a
certain amount of hydraulic power is needed at the bit; therefore, the freight
must be paid by supplying additional hydraulic power at the surface to pay the
way to the bottom and to lift the cuttings to the surface.
Several factors influence the amount of hydraulic energy expended to overcome
friction losses, including fluid velocity. Figure 3.1 (Page 3-8) illustrates two types
of flow: laminar flow (slow) and turbulent flow (fast). Normally, laminar flow in
the drillpipe occurs at extremely low pump rates with fluid velocities of 1 to
2 ft/sec. Even heavy, thick muds flow smoothly. However, the drag of the fluid
against the wall of the pipe and the internal friction of the fluid itself (viscosity)
combine to create friction losses.
In normal drilling operations, turbulent flow is much more common. At these
higher fluid velocities, drag from the pipe walls and changes in ID caused by
tool joints cause eddies to form in the flow patterns. These eddies are small
whirlpools that move within the main flowstream causing counterflow and
crossflow, which creates turbulence. Turbulent flow requires more energy than
smooth or laminar flow. The faster the flow, the greater the amount of energy
that is absorbed by the turbulence and the greater the hydraulic power loss.
3-6
October 1996
Hydrostatic
Pressure at
Bottom of
Component
(psi)
Total Pressure
at Bottom of
Component
(psi)
Pressure
Gauge
2,900
Surface
Connections
25
25
2,875
Drillpipe
14,300
673
698
12,247
14,449
Drill Collars
15,000
150
848
12,846
14,898
Bit
15,000
1,852
2,700
12,846
13,046
Depth at Top of
Component
Component (ft)
Pressure Drop
Across
Component
(psi)
Total Pressure
Hydrostatic
Total Pressure
Drop to Top of Pressure at Top
at Top of
Component
of Component
Component
(psi)
(psi)
(psi)
Bit
15,000
1,852
2,700
12,846
13,046
Drill Collar in
Open Hole
14,300
54
2,754
12,247
12,393
Drillpipe in
Open Hole
12,000
34
2,788
10,227
10,389
Drillpipe in
Casing
112
2,900
October 1996
Drilling Hydraulics
3-7
Laminar Flow
Slow
Less
Energy
Required
Turbulent Flow
Fast
More
Energy
Required
3-8
October 1996
Examples 4 and 5 show applications of Equation 3.3 and Equation 3.1 for
hydraulic horsepower. Problem 5 requires Equation 3.1 and Equation 3.3.
= 10,000 ft
= 3.826 in.
= (7.7 x 10-5) x (MW0.8 x Q1.8) x (PV0.2 x L) D4.8 ............................. (3.3)
= (7.7 x 10-5) x (100.8 x 2101.8) x (250.2 x 10,000) 3.8264.8
= 0.000077 x (6.301 x 15,135.429) x (1.904 x 10,000) 626.828
= 223.056 psi
October 1996
Drilling Hydraulics
3-9
Problem 5
What is the hydraulic power loss (hhp) in 5,000 ft of 3 1/2-in., 15.50-lb/ft drillpipe
when operators are circulating 15.0-lb/gal mud with a plastic viscosity of 50 cp
at 150 gal/min?
Work Space
Answer ____________
(The solution for Problem 5 is on Page 3-23.)
3-10
October 1996
Pressure Drop
(psi)
Power Loss
(hhp)
210
223
27
420
778
191
630
1,613
593
210
223
308
338
420
778
1,076
1,354
630
1,613
2,231
2,809
The muds viscosity also influences the pressure and power losses in the system,
although not as significantly as the other factors. For example, increasing the
plastic viscosity from 25 to 40 cp only increases the pressure losses by approximately 10%.
Another major factor influencing the pressure and power losses is the drillpipe
ID. With a small ID, the fluid velocity must be greater for a given rate, creating
higher turbulence and greater pressure and power loss. Table 3.5 (Page 3-12)
compares the pressure losses for 10,000 ft of 3 1/2-in., 15.50-lb/ft to 4 1/2-in.,
16.60-lb/ft drillpipe at three different circulating rates when 10.0-lb/gal mud
with a 25-cp plastic viscosity is pumped. Some of these pressure drops are
excessive and are shown for comparison only. Decreasing the drillpipe size from
4 1/ 2-in., 16.60-lb/ft to 3 1/2-in., 15.50-lb/ft increases the pressure losses by approximately six and one-third times. Even at reduced circulating rates commonly used with smaller drillpipe, pressure losses are still high.
Because of the influence of the pipe ID, drillpipe size for a given hole size
should be reasonably large, yet not so large that it causes an excessive backpressure on the formation from high annular-return velocity.
October 1996
Drilling Hydraulics
3-11
210
223
1,421
420
778
4,948
630
1,613
10,266
flow rate
fluid density
mud viscosity
drillpipe ID
Pressure and power losses in the drill collars are similar to those for drillpipe
and are influenced by the same factors as the drillpipe. The reduced ID in the
drill collars increases the velocity and causes a higher friction loss per foot than
in drillpipe. Fortunately, drill collars are much shorter than drillpipe.
Bit Hydraulics
As drilling fluid enters the water courses of the bit and exits the bit nozzle, its
flow rate is greatly increased. Fluid travels through the drillpipe at about
10 ft/sec. As it exits the nozzles of the bit, the fluid may be traveling in excess of
400 ft/sec (more than 270 mile/hr). The increase in kinetic energy for each
gallon of 10.0-lb/gal fluid is even greaterfrom about 15 ft/lb to approximately
25,000 ft/lb of energy.
Just as it is with the drillpipe, the system must pay for transportation of the fluid
through jets with a pressure drop in the entire system. With two-thirds of the
total pressure drop as an average, the drop across the bit is about twice the
pressure drop across the rest of the system. In a well-balanced hydraulic system,
the pressure drop across the nozzles ranges from one-half to three-quarters of
the entire systems pressure drop.
3-12
October 1996
What is the nozzle velocity if three Number 8 jets are used with a flow
rate of 210 gal/min?
Solution
Diameter of Number 8 jet = 8/ 32 in. = 0.25 in.
Area of one jet = 0.7854 x 0.25 in. x 0.25 in. = 0.049 in.2
AN = 3 jets x 0.049 in.2 = 0.147 in.2
Q = 210 gal/min
NV = 0.32 x Q AN .............................................................................. (3.4)
= 0.32 x 210 gal/min 0.147 in. 2 = 457.143 ft/sec
October 1996
Drilling Hydraulics
3-13
Use the conditions for Example 6. What is the pressure drop across
the bit if the mud weight is 10.0 lb/gal?
Solution
MW = 10.0 lb/gal
NV = 457.143 ft/sec (from Example 6)
P = MW x NV2 1,120 ....................................................................... (3.5)
= 10.0 lb/gal x (457.143 ft/sec)2 1,120 = 1,865.889 psi
Problem 6
Two Number 16 jets are used with 15.0-lb/gal mud at a 210-gal/min flow rate.
A. What is the nozzle velocity?
Work Space
Answer ____________
B. What is the pressure loss through the bit?
Work Space
Answer ____________
(The solution for Problem 6 is on Page 3-23.)
3-14
October 1996
mud weight
flow rate
nozzle size
Increasing the nozzle area reduces both the velocity and the pressure drop across
the bit. When the mud weight is increased, the pressure drop increases proportionately. Larger flow rates also increase the pressure drop across the bit.
Table 3.6 shows nozzle exit velocities for various flow rates and nozzle sizes.
Some of the high velocities shown in the table are unattainable; they are shown
to illustrate the importance of nozzle selection. Doubling the flow rate doubles
the exit velocity at the bit nozzles (from 210 gal/min to 420 gal/min) and increases the velocity (from 457 ft/sec to 914 ft/sec for three Number 8 nozzles).
Doubling the nozzle diameter (from three Number 8 jets to three Number 16 jets)
quadruples the nozzle area (from 0.147 in.2 to 0.589 in.2) and reduces the velocity
by a factor of four (457 ft/sec 4 114 ft/sec).
Flow Rate
(gal/min)
210
457
203
114
420
914
406
228
840
1,828
812
456
Table 3.7, Page 3-16, shows the pressure drops with the same nozzles and rates
as Table 3.6. Several of the pressure drops shown are not attainable, but can be
used for comparison. Notice that fluid density (mud weight) is an important
factor affecting the pressure drop across the nozzles. Doubling the mud weight
(from 10 lb/gal to 20 lb/gal) also doubles the pressure drop across the nozzles
(1,866 psi x 2 = 3,732 psi at 210 gal/min using three Number 8 jets).
Nozzle size also affects pressure. At 210 gal/min with 10-lb/gal mud, doubling
the nozzle diameters (three Number 8 jets to three Number 16 jets) reduces the
pressure drop by a factor of 16 (1,866 psi 16 = 116.6 psi). Flow rate also affects
the pressure drop. With 10.0-lb/gal mud and three Number 8 jets, doubling the
flow rate (from 210 gal/min to 420 gal/min) increases the pressure drop by a
factor of four (1,866 psi x 4 = 7,464 psi).
October 1996
Drilling Hydraulics
3-15
Power is necessary to remove cuttings from the bottom of the hole. Since it is
normally necessary to maintain the hydrostatic pressure at the bottom of the
hole at a higher value than the pressure in the pores of the formation, the cuttings are securely held against the face of the rock. The high-velocity jetting
action causes the drilling fluid to penetrate among the cuttings and even into the
minute fractures on the bottom of the hole, partially equalizing the differential
pressure existing at the rock face that otherwise tends to hold the cuttings down.
Reducing this differential pressure then allows the high-velocity fluid to remove
the cuttings quickly and easily. Figure 3.2 illustrates this effect.
210
420
840
3-16
10
1,866
368
116
15
2,799
552
174
20
3,732
736
232
10
7,464
1,472
465
15
11,195
2,208
697
20
14,927
2,944
929
10
29,854
5,888
1,860
15
44,781
8,832
2,789
20
59,708
11,776
3,719
October 1996
High-velocity
fluid-jet action
releases chips
fractured by
bit teeth.
Hydrostatic pressure
causes chip
hold-down.
October 1996
Drilling Hydraulics
3-17
Annular Hydraulics
Annular hydraulic principles differ from drillpipe or bit hydraulic principles in
several ways. First, annular flow is much slower; in fact, flow in the annulus is
normally considered to be laminar as opposed to the turbulent flow inside the
pipe. Second, the shape of the flow passage is not just round but generally is
considered more doughnut-shaped, as shown in Figure 3.3. Even this assumption does not generally hold true. Since the pipe is not always centered in the
hole, the annular flow passage is actually more crescent-shaped (Figure 3.4).
However, for calculation purposes (since the cross-sectional areas are the same)
the doughnut approach is usually used. Third, the irregularities in the hole
(washed-out sections or sloughing formations) cause the openhole section to
disturb the laminar flow pattern. Fourth, the rotation of the pipe (as crescent
revolves around the inside of the hole) also tends to break up the laminar flow in
the annulus.
Doughnut-Shaped
Annulus
Drillpipe
Figure 3.3
Crescent-Shaped
Annulus
Drillpipe
Figure 3.4
3-18
October 1996
During slow, hard rock drilling, an annular velocity of 1 1/2 to 2 ft/sec (about 100
to 125 ft/min) is adequate to bring cuttings to the surface. For fast top-hole
drilling, experience shows that higher annular velocities will be required, especially when laminar flow exists.
The principles that apply to flow in the drillpipe also apply to the annular flow.
The higher the flow rate, the greater the pressure drop caused by friction. Similarly, high-viscosity mud also increases the annular pressure drop slightly; the
backpressure at the bottom increases, which tends to hold down the chips.
175 PD (PW - MW )
MW 0.333 cp0.333
0 . 667
........................................................................... (3.6)
where
SV
175
PD
PW
MW
= Constant
= Particle (cutting) diameter, in.
= Particle weight, lb/gal (normally about 21.0 lb/gal)
= Mud weight, lb/gal
cp
= Mud viscosity, cp
October 1996
Drilling Hydraulics
3-19
What is the slip velocity of 0.20-in. diameter cuttings in 10 lb/gal of 40cp mud?
Solution
PD = 0.20 in.
PW = 21.0 lb/gal
MW = 10.0 lb/gal
cp = 40 cp
SV =
175 PD (PW - MW )
0.667
MW 0.333 CP0.333
175 0.20 ( 2.10 -10.0)
........................................................... (3.6)
0.667
10.00.333 40 0.333
175 0.20 4.9500
= 23.561 ft / min
2.153 3.146
Problem 7
What is the slip velocity of 0.30-in. diameter cuttings when 9.5-lb/gal mud with
an 89-cp viscosity is circulated?
Work Space
Answer ____________
(The solution for Problem 7 is on Page 3-23.)
3-20
October 1996
40
80
October 1996
Mud Weight
(lb/gal)
0.30
0.40
10
23.6
35.3
47.1
20
3.8
5.7
7.6
10
18.7
28.1
37.4
20
3.0
4.5
6.0
Drilling Hydraulics
3-21
Solutions to Problems
Pages 3-22 and 3-23 list the solutions to the practice problems in Chapter 3. Most
of the problems can be solved more than one way. Different methods may give
slightly different answers, depending on how the numbers are rounded off.
NOTE
If you use and understand a particular method, always use it, even if it is not
used in this text.
3-22
October 1996
= 150 gal/min
= 50 cp
= 5,000 ft
= 2.602 in.
= (7.7 x 10-5) x (MW0.8 x Q1.8) x (PV0.2 x L) D4.8 .............................................................................. (3.3)
October 1996
Drilling Hydraulics
3-23
Notes
3-24
October 1996